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US20090285854A1 - Frozen stockpiling of influenza vaccines - Google Patents

Frozen stockpiling of influenza vaccines Download PDF

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Publication number
US20090285854A1
US20090285854A1 US12/374,015 US37401507A US2009285854A1 US 20090285854 A1 US20090285854 A1 US 20090285854A1 US 37401507 A US37401507 A US 37401507A US 2009285854 A1 US2009285854 A1 US 2009285854A1
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vaccine
bulk
influenza
preparing
virus
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Mario Contorni
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Novartis AG
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Novartis AG
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K39/00—Medicinal preparations containing antigens or antibodies
    • A61K39/12—Viral antigens
    • A61K39/145—Orthomyxoviridae, e.g. influenza virus
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K39/00—Medicinal preparations containing antigens or antibodies
    • A61K39/12—Viral antigens
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P31/00—Antiinfectives, i.e. antibiotics, antiseptics, chemotherapeutics
    • A61P31/12—Antivirals
    • A61P31/14—Antivirals for RNA viruses
    • A61P31/16—Antivirals for RNA viruses for influenza or rhinoviruses
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K39/00—Medicinal preparations containing antigens or antibodies
    • A61K2039/51—Medicinal preparations containing antigens or antibodies comprising whole cells, viruses or DNA/RNA
    • A61K2039/525—Virus
    • A61K2039/5252—Virus inactivated (killed)
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K39/00—Medicinal preparations containing antigens or antibodies
    • A61K2039/51—Medicinal preparations containing antigens or antibodies comprising whole cells, viruses or DNA/RNA
    • A61K2039/525—Virus
    • A61K2039/5254—Virus avirulent or attenuated
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12N—MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA
    • C12N2760/00—MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA ssRNA viruses negative-sense
    • C12N2760/00011—Details
    • C12N2760/16011—Orthomyxoviridae
    • C12N2760/16111—Influenzavirus A, i.e. influenza A virus
    • C12N2760/16134—Use of virus or viral component as vaccine, e.g. live-attenuated or inactivated virus, VLP, viral protein

Definitions

  • This invention is in the field of manufacturing vaccines against influenza virus infection.
  • Influenza vaccines currently in general use are described in more detail in chapters 17 & 18 of reference 1. They are based on live virus or inactivated virus, and inactivated vaccines can be based on whole virus, ‘split’ virus or on purified surface antigens (including haemagglutinin and neuraminidase).
  • Haemagglutinin (HA) is the main immunogen in inactivated influenza vaccines, and vaccine doses are standardized by reference to HA levels, with vaccines typically containing about 15 ⁇ g of HA per strain.
  • Vaccine stockpiles also create logistical problems.
  • a typical vaccine box is about 80 ⁇ 40 ⁇ 40 mm, and so 10 million vaccine doses require about 1,250 m 3 (1,250,000 liters) of refrigerated storage space. It is a further object of the invention to provide ways in which these logistical problems can be avoided.
  • the manufacturing process for current trivalent split or subunit influenza vaccines typically involves the following steps: growth of virus; purification of virus; inactivation of virus; disruption of virions or purification of surface glycoproteins to give bulk antigen; dilution of antigens to give final HA concentration of 15 ⁇ g/dose; repetition of these steps for two other strains; combination of antigens from the three strains; dose filling; and packaging.
  • the present invention prepares and stockpiles bulk vaccine.
  • the later steps in vaccine manufacture can be carried out very quickly and so, in the event of a pandemic outbreak, the bulk could mobilized to allow rapid preparation of final vaccines while avoiding the time-consuming steps of virus growth, purification and inactivation.
  • the bulk vaccine can be stored under conditions that extend the shelf-life relative to final vaccines (e.g. it can be frozen), while the higher antigen concentration and absence of packaging materials (boxes, vials, etc.) means that the storage space requirements are hugely reduced e.g.
  • the material for 10 million monovalent vaccines at a bulk concentration of 500 ⁇ g/ml could be stored in much less than 1 m 3 .
  • the invention is particularly useful in stockpiling for potential pandemic situations, but can also be used in inter-pandemic periods.
  • the invention provides a process for preparing an influenza vaccine bulk, comprising the steps of: (a) preparing bulk vaccine antigen from a source of influenza virus; and (b) storing under frozen conditions the bulk vaccine prepared in step (a).
  • the process may include a previous step of growing influenza virus, and so step (a) will involve preparing bulk vaccine antigen from the viruses grown in that step.
  • the invention also provides a process for preparing an influenza vaccine from such a frozen bulk vaccine, comprising these steps and then the steps of: (c) thawing the frozen bulk vaccine; and (d) preparing a final vaccine for administration to patients from the bulk vaccine.
  • the invention also provides a process for preparing an influenza vaccine, comprising the steps of: (a) obtaining a bulk vaccine that has been stored under frozen conditions; and (b) preparing a final vaccine for administration to patients from the bulk vaccine. If the vaccine obtained in step (a) is still frozen then a thawing step will be included within or before step (b).
  • influenza viruses that have been grown on a suitable substrate.
  • Substrates currently in use for growing influenza viruses include eggs and cell culture.
  • the current standard method for influenza virus growth uses specific pathogen-free (SPF) embryonated hen eggs, with virus being purified from the egg contents (allantoic fluid). More recently, however, viruses have been grown in animal cell culture and, for reasons of speed and patient allergies, this growth method is preferred. If egg-based viral growth is used then one or more amino acids may be introduced into the allantoic fluid of the egg together with the virus [47].
  • SPPF pathogen-free
  • the viral growth substrate will typically be a cell line of mammalian origin.
  • suitable mammalian cells of origin include, but are not limited to, hamster, cattle, primate (including humans and monkeys) and dog cells.
  • Various cell types may be used, such as kidney cells, fibroblasts, retinal cells, lung cells, etc.
  • suitable hamster cells are the cell lines having the names BHK21 or HKCC.
  • Suitable monkey cells are e.g. African green monkey cells, such as kidney cells as in the Vero cell line.
  • Suitable dog cells are e.g. kidney cells, as in the MDCK cell line.
  • suitable cell lines include, but are not limited to: MDCK; CHO; 293T; BHK; Vero; MRC-5; PER.C6; WI-38; etc.
  • Preferred mammalian cell lines for growing influenza viruses include: MDCK cells [3-6], derived from Madin Darby canine kidney; Vero cells [7-9], derived from African green monkey ( Cercopithecus aethiops ) kidney; or PER.C6 cells [10], derived from human embryonic retinoblasts.
  • MDCK cells [3-6] derived from Madin Darby canine kidney
  • Vero cells 7-9
  • PER.C6 cells derived from human embryonic retinoblasts.
  • These cell lines are widely available e.g. from the American Type Cell Culture (ATCC) collection [11], from the Coriell Cell Repositories [12], or from the European Collection of Cell Cultures (ECACC).
  • ATCC American Type Cell Culture
  • ECACC European Collection of Cell Cultures
  • the ATCC supplies various different Vero cells under catalog numbers CCL-81, CCL-81.2, CRL-1586 and CRL-1587, and it supplies MDCK cells under catalog number CCL-34.
  • PER.C6 is available from the ECACC under deposit number 96022940.
  • virus can be grown on avian cell lines [e.g. refs. 13-15], including cell lines derived from ducks (e.g. duck retina) or hens.
  • avian cell lines include avian embryonic stem cells [13,16] and duck retina cells [14].
  • Suitable avian embryonic stem cells include the EBx cell line derived from chicken embryonic stem cells, EB45, EB14, and EB14-074 [17].
  • Chicken embryo fibroblasts (CEF) may also be used.
  • the most preferred cell lines for growing influenza viruses are MDCK cell lines.
  • the original MDCK cell line is available from the ATCC as CCL-34, but derivatives of this cell line may also be used.
  • reference 3 discloses a MDCK cell line that was adapted for growth in suspension culture (‘MDCK 33016’, deposited as DSM ACC 2219).
  • reference 18 discloses a MDCK-derived cell line that grows in suspension in serum-free culture (‘B-702’, deposited as FERM BP-7449).
  • Reference 19 discloses non-tumorigenic MDCK cells, including ‘MDCK-S’ (ATCC PTA-6500), ‘MDCK-SF101’ (ATCC PTA-6501), ‘MDCK-SF102’ (ATCC PTA-6502) and ‘MDCK-SF103’ (PTA-6503).
  • Reference 20 discloses MDCK cell lines with high susceptibility to infection, including ‘MDCK.5F1’ cells (ATCC CRL-12042). Any of these MDCK cell lines can be used.
  • virus may be grown on cells in suspension [3,21,22] or in adherent culture.
  • a suitable MDCK cell line for suspension culture is MDCK 33016 (deposited as DSM ACC 2219).
  • microcarrier culture can be used.
  • Cell lines supporting influenza virus replication are preferably grown in serum-free culture media and/or protein free media.
  • a medium is referred to as a serum-free medium in the context of the present invention in which there are no additives from serum of human or animal origin.
  • Protein-free is understood to mean cultures in which multiplication of the cells occurs with exclusion of proteins, growth factors, other protein additives and non-serum proteins, but can optionally include proteins such as trypsin or other proteases that may be necessary for viral growth. The cells growing in such cultures naturally contain proteins themselves.
  • Cell lines supporting influenza virus replication are preferably grown below 37° C. [23] e.g. 30-36° C. during viral replication.
  • virus is grown on a cell line then the growth culture, and also the viral inoculum used to start the culture, is preferably free from (i.e. will have been tested for and given a negative result for contamination by) herpes simplex virus, respiratory syncytial virus, parainfluenza virus 3, SARS coronavirus, adenovirus, rhinovirus, reoviruses, polyomaviruses, birnaviruses, circoviruses, and/or parvoviruses [24]. Absence of herpes simplex viruses is particularly preferred.
  • the method for propagating virus in cultured cells generally includes the steps of inoculating the cultured cells with the strain to be cultured, and then cultivating the infected cells for a desired time period for virus propagation, such as for example as determined by virus titer or antigen expression (e.g. between 24 and 168 hours after inoculation).
  • the cultured cells are inoculated with a virus (measured by PFU or TCID 50 ) to cell ratio of 1:500 to 1:1, preferably 1:100 to 1:5, more preferably 1:50 to 1:10.
  • the virus is added to a suspension of the cells or is applied to a monolayer of the cells, and the virus is absorbed on the cells for at least 60 minutes but usually less than 300 minutes, preferably between 90 and 240 minutes at 25° C. to 40° C., preferably 28° C. to 37° C.
  • the infected cell culture e.g. monolayers
  • the infected cell culture may be removed either by freeze-thawing or by enzymatic action to increase the viral content of the harvested culture supernatants.
  • Harvested fluids may then be either inactivated (see below).
  • Cultured cells may be infected at a multiplicity of infection (“m.o.i.”) of about 0.0001 to 10, preferably 0.002 to 5, more preferably to 0.001 to 2.
  • the cells are infected at a m.o.i of about 0.01. Infected cells may be harvested 30 to 60 hours post infection. Preferably, the cells are harvested 34 to 48 hours post infection. Still more preferably, the cells are harvested 38 to 40 hours post infection.
  • Proteases typically trypsin
  • the proteases can be added at any suitable stage during the culture.
  • Influenza virus strains used in vaccines change from season to season.
  • trivalent vaccines are typical, including two influenza A strains (H1N1 and H3N2) and one influenza B strain.
  • the invention can be used with inter-pandemic strains of this type, but it is more useful with viruses from pandemic strains (i.e. strains to which the vaccine recipient and the general human population are immunologically na ⁇ ve), such as H2, H5, H7 or H9 subtype strains (in particular of influenza A virus), and influenza vaccines for pandemic strains may be monovalent or may, for instance, be based on a normal trivalent vaccine supplemented by a pandemic strain.
  • the invention may protect against one or more of HA subtypes H1, H2, H3, H4, H5, H6, H7, H8, H9, H10, H11, H12, H13, H14, H15 or H16.
  • the invention may protect against one or more of influenza A virus NA subtypes N1, N2, N3, N4, N5, N6, N7, N8 or N9.
  • an influenza strain that give it the potential to cause a pandemic outbreak are: (a) it contains a new hemagglutinin compared to the hemagglutinins in currently-circulating human strains, i.e. one that has not been evident in the human population for over a decade (e.g. H2), or has not previously been seen at all in the human population (e.g. H5, H6 or H9, that have generally been found only in bird populations), such that the human population will be immunologically na ⁇ ve to the strain's hemagglutinin; (b) it is capable of being transmitted horizontally in the human population; and (c) it is pathogenic to humans.
  • a new hemagglutinin compared to the hemagglutinins in currently-circulating human strains, i.e. one that has not been evident in the human population for over a decade (e.g. H2), or has not previously been seen at all in the human population (e.g. H5, H6 or H
  • a virus with H5 haemagglutinin type is preferred for immunising against pandemic influenza, such as a H5N1 strain.
  • Other possible strains include H5N3, H9N2, H2N2, H7N1 and H7N7, and any other emerging potentially pandemic strains.
  • a virus may fall into HA clade 1, HA clade 1′, HA clade 2 or HA clade 3 [25], with clades 1 and 3 being particularly relevant.
  • Influenza virus strains used with the invention may be resistant to antiviral therapy (e.g. resistant to oseltamivir [26] and/or zanamivir), including resistant pandemic strains [27].
  • Influenza virus strains used with the invention may be attenuated. They may be temperature-sensitive. They may be cold-adapted. These three features are particularly useful when using live virus as an antigen.
  • the influenza virus may be a reassortant strain, and may have been obtained by reverse genetics techniques.
  • Reverse genetics techniques [e.g. 28-32] allow influenza viruses with desired genome segments to be prepared in vitro using plasmids. Typically, they involve expressing (a) DNA molecules that encode desired viral RNA molecules e.g. from poll promoters, and (b) DNA molecules that encode viral proteins e.g. from polII promoters, such that expression of both types of DNA in a cell leads to assembly of a complete intact infectious virion.
  • the DNA preferably provides all of the viral RNA and proteins, but it is also possible to use a helper virus to provide some of the RNA and proteins.
  • Plasmid-based methods using separate plasmids for producing each viral RNA are preferred [33-35], and these methods will also involve the use of plasmids to express all or some (e.g. just the PB1, PB2, PA and NP proteins) of the viral proteins, with up to 12 plasmids being used in some methods.
  • RNA polymerase 1 transcription cassettes for viral RNA synthesis
  • plasmid e.g. sequences encoding 1, 2, 3, 4, 5, 6, 7 or all 8 influenza A vRNA segments
  • protein-coding regions with RNA polymerase II promoters on another plasmid e.g. sequences encoding 1, 2, 3, 4, 5, 6, 7 or all 8 influenza A mRNA transcripts.
  • Preferred aspects of the reference 36 method involve: (a) PB 1, PB2 and PA mRNA-encoding regions on a single plasmid; and (b) all 8 vRNA-encoding segments on a single plasmid. Including the NA and HA segments on one plasmid and the six other segments on another plasmid can also facilitate matters.
  • bacteriophage polymerase promoters As an alternative to using poll promoters to encode the viral RNA segments, it is possible to use bacteriophage polymerase promoters [37]. For instance, promoters for the SP6, T3 or T7 polymerases can conveniently be used. Because of the species-specificity of poll promoters, bacteriophage polymerase promoters can be more convenient for many cell types (e.g. MDCK), although a cell must also be transfected with a plasmid encoding the exogenous polymerase enzyme.
  • bacteriophage polymerase promoters can be more convenient for many cell types (e.g. MDCK), although a cell must also be transfected with a plasmid encoding the exogenous polymerase enzyme.
  • the virus may include one or more RNA segments from a A/PR/8/34 virus (typically 6 segments from A/PR/8/34, with the HA and N segments being from a vaccine strain, i.e. a 6:2 reassortant), particularly when viruses are grown in eggs. It may also include one or more RNA segments from a A/WSN/33 virus, or from any other virus strain useful for generating reassortant viruses for vaccine preparation.
  • the invention protects against a strain that is capable of human-to-human transmission, and so the strain's genome will usually include at least one RNA segment that originated in a mammalian (e.g. in a human) influenza virus. It may include NS segment that originated in an avian influenza virus.
  • the HA encoded by the influenza virus may be a natural HA as found in a wild-type virus, or it may have been modified. For instance, it is known to modify HA to remove determinants (e.g. hyper-basic regions around the cleavage site between HA1 and HA2) that cause a virus to be highly pathogenic in avian species, as these determinants can otherwise prevent viral growth in eggs.
  • determinants e.g. hyper-basic regions around the cleavage site between HA1 and HA2
  • influenza vaccines from material derived from influenza virions
  • proteins in heterologous recombinant hosts.
  • HA can be expressed in an insect cell line using a baculovirus vector [40,41], as can neuraminidase [42].
  • the invention may therefore involve a step of growing a recombinant host that expresses an influenza virus antigen, and preparing bulk vaccine from the recombinant host.
  • the bulk vaccine may include live virus or inactivated virus.
  • Live viruses are known to retain immunogenicity after frozen storage, as MedImmune's FLUMISTTM product (trivalent live virus) is stored in a freezer at or below ⁇ 15° C. prior to use.
  • the bulk vaccine includes live virus
  • the bulk will be prepared by a process that comprises growing the virus on a suitable substrate and then purifying virions from virion-containing fluids.
  • the fluids may be clarified by centrifugation, and stabilized with buffer (e.g. containing sucrose, potassium phosphate, and monosodium glutamate).
  • a procedure may involve a virion purification step followed by an inactivation step, or the inactivation can take place at the same time as purification.
  • a purification process may involve zonal centrifugation using a linear sucrose gradient solution that includes detergent for simultaneous inactivation (e.g. splitting) of virions.
  • Chemical methods for inactivating a virus include treatment with an effective amount of one or more of the following agents: detergents, formaldehyde, ⁇ -propiolactone, or UV light. Additional chemical means for inactivation include treatment with methylene blue, psoralen, carboxyfullerene (C60) or a combination of any thereof. Other methods of viral inactivation are known in the art, such as for example binary ethylamine, acetyl ethyleneimine, or gamma irradiation.
  • Split virions are obtained by treating virions with detergents (e.g. ethyl ether, polysorbate 80, deoxycholate, tri-N-butyl phosphate, Triton X-100, Triton N101, cetyltrimethylammonium bromide, etc.) to produce subvirion preparations, including the ‘Tween-ether’ splitting process.
  • detergents e.g. ethyl ether, polysorbate 80, deoxycholate, tri-N-butyl phosphate, Triton X-100, Triton N101, cetyltrimethylammonium bromide, etc.
  • Methods of splitting influenza viruses are well known in the art e.g. see refs. 43-48, etc.
  • Splitting of the virus is typically carried out by disrupting or fragmenting whole virus, whether infectious or non-infectious with a disrupting concentration of a splitting agent. The disruption results in a full or partial solubilisation of the virus proteins, altering the integrity
  • Preferred splitting agents are non-ionic and ionic (e.g. cationic) surfactants e.g. alkylglycosides, alkylthioglycosides, acyl sugars, sulphobetaines, betains, polyoxyethylenealkylethers, N,N-dialkyl-Glucamides, Hecameg, alkylphenoxy-polyethoxyethanols, quaternary ammonium compounds, sarcosyl, CTABs (cetyl trimethyl ammonium bromides), tri-N-butyl phosphate, Cetavlon, myristyltrimethylammonium salts, lipofectin, lipofectamine, and DOT-MA, the octyl- or nonylphenoxy polyoxyethanols (e.g.
  • Triton surfactants such as Triton X-100 or Triton N101
  • polyoxyethylene sorbitan esters the Tween surfactants
  • polyoxyethylene ethers polyoxyethlene esters, etc.
  • One useful splitting procedure uses the consecutive effects of sodium deoxycholate and formaldehyde and, as mentioned above, splitting can take place during initial virion purification (e.g. in a sucrose density gradient solution).
  • Split virions can usefully be resuspended in sodium phosphate-buffered isotonic sodium chloride solution.
  • Purified surface antigen vaccines comprise the influenza surface antigens haemagglutinin and, typically, also neuraminidase. Processes for purifying these proteins from virions after viral growth are well known in the art.
  • Virosomes can be prepared by solubilization of influenza virus with a detergent followed by removal of the nucleocapsid and reconstitution of the membrane containing the viral glycoproteins.
  • An alternative method for preparing virosomes involves adding viral membraneglycoproteins to excess amounts of phospholipids, to give liposomes with viral proteins in their membrane.
  • the invention can be used to store bulk virosomes.
  • the HA concentration in the stored bulk will typically have be in the range of 75-1000 ⁇ g/ml. Within this range, the concentration will generally be at least 100 ⁇ g/ml e.g. ⁇ 150 ⁇ g/ml, ⁇ 200 ⁇ g/ml, ⁇ 250 ⁇ g/ml, ⁇ 300 ⁇ g/ml, ⁇ 350 ⁇ g/ml, ⁇ 400 ⁇ g/ml, ⁇ 450 ⁇ g/ml, ⁇ 500 ⁇ g/ml, ⁇ 550 ⁇ g/ml, ⁇ 600 ⁇ g/ml, ⁇ 650 ⁇ g/ml, ⁇ 700 ⁇ g/ml, ⁇ 750 ⁇ g/ml, etc.
  • the concentration will depend on factors such as the influenza strain, the growth substrate, etc. Higher HA concentrations mean that a lower storage volume is required for a fixed number of final doses.
  • the bulk will usually contain also neuraminidase (NA).
  • the bulk may include matrix protein, in order to benefit from additional T cell epitopes. It may include M1 and/or M2 matrix protein, and including detectable levels of M1 matrix protein (or fragments thereof) is preferred. Nucleoprotein may also be present.
  • TCID 50 median tissue culture infectious dose
  • TCID 50 TCID 50
  • Stored bulk material will have a higher TCID 50 e.g. at least 10 9 or 10 10 per ml of bulk.
  • Bulk compositions of live or inactivated antigens may include detergent e.g. a polyoxyethylene sorbitan ester surfactant (known as ‘Tweens’), an octoxynol (such as octoxynol-9 (Triton X-100) or t-octylphenoxypolyethoxyethanol), a cetyl trimethyl ammonium bromide (‘CTAB’), or sodium deoxycholate, particularly for a split or surface antigen vaccine.
  • the detergent may be present only at trace amounts.
  • bulk vaccines stored according to the invention will generally be monovalent (although they may later be used to prepare multivalent vaccines). Storage of monovalent material maintains post-storage flexibility e.g. in choosing which bulks to mix if a multivalent vaccine is desired, etc. While the stored bulk may include antigens from more than one (e.g. 2, 3, 4 or more) influenza virus strains, therefore, it is preferred that it should contain antigen from a single strain, which may be an influenza B virus or, more preferably, an influenza A virus. Storage of influenza B virus is advantageous as it rarely changes from season-to-season, and so stored material can be used for more than one season. Storage of influenza A virus is advantageous because of potential pandemic outbreaks.
  • the bulk vaccine will advantageously be free from egg proteins (e.g. ovalbumin and ovomucoid) and from chicken DNA, thereby reducing allergenicity in the final vaccine product.
  • egg proteins e.g. ovalbumin and ovomucoid
  • a bulk preferably contains less than 10 ng (preferably less than 1 ng, and more preferably less than 100 pg) of residual host cell DNA per 15 ⁇ g of HA, although trace amounts of host cell DNA may be present.
  • the host cell DNA that it is desirable to exclude from compositions of the invention is DNA that is longer than 100 bp.
  • the assay used to measure DNA will typically be a validated assay [53,54].
  • the performance characteristics of a validated assay can be described in mathematical and quantifiable terms, and its possible sources of error will have been identified.
  • the assay will generally have been tested for characteristics such as accuracy, precision, specificity. Once an assay has been calibrated (e.g. against known standard quantities of host cell DNA) and tested then quantitative DNA measurements can be routinely performed.
  • hybridization methods such as Southern blots or slot blots [55]
  • immunoassay methods such as the ThresholdTM System [56]
  • quantitative PCR [57].
  • hybridization methods such as Southern blots or slot blots [55]
  • immunoassay methods such as the ThresholdTM System [56]
  • quantitative PCR [57]
  • These methods are all familiar to the skilled person, although the precise characteristics of each method may depend on the host cell in question e.g. the choice of probes for hybridization, the choice of primers and/or probes for amplification, etc.
  • the ThresholdTM system from Molecular Devices is a quantitative assay for picogram levels of total DNA, and has been used for monitoring levels of contaminating DNA in biopharmaceuticals [56].
  • a typical assay involves non-sequence-specific formation of a reaction complex between a biotinylated ssDNA binding protein, a urease-conjugated anti-ssDNA antibody, and DNA. All assay components are included in the complete Total DNA Assay Kit available from the manufacturer. Various commercial manufacturers offer quantitative PCR assays for detecting residual host cell DNA e.g. AppTecTM Laboratory Services, BioRelianceTM, Althea Technologies, etc. A comparison of a chemiluminescent hybridisation assay and the total DNA ThresholdTM system for measuring host cell DNA contamination of a human viral vaccine can be found in reference 58.
  • Contaminating DNA can be removed during bulk preparation using standard purification procedures e.g. chromatography, etc. Removal of residual host cell DNA can be enhanced by nuclease treatment e.g. by using a DNase.
  • nuclease treatment e.g. by using a DNase.
  • a convenient method for reducing host cell DNA contamination during bulk manufacture is disclosed in references 59 & 60, involving a two-step treatment, first using a DNase (e.g. Benzonase), which may be used during viral growth, and then a cationic detergent (e.g. CTAB), which may be used during virion disruption.
  • a DNase e.g. Benzonase
  • CTAB cationic detergent
  • Material containing ⁇ 10 ng (e.g. ⁇ 1 ng, ⁇ 100 pg) host cell DNA per 15 ⁇ g of HA are preferred.
  • Material containing ⁇ 10 ng (e.g. ⁇ 1 ng, ⁇ 100 pg) host cell DNA per 50 ⁇ g of HA are more preferred.
  • the average length of any residual host cell DNA is less than 500 bp e.g. less than 400 bp, less than 300 bp, less than 200 bp, less than 100 bp, etc.
  • the host cell DNA that it is desirable to exclude from compositions of the invention is DNA that is longer than 100 bp.
  • a final vaccine is to be adjuvanted by a combination of an immunostimulatory oligonucleotide and an emulsion then the oligonucleotide may be present in the stored bulk whereas the emulsion may be absent.
  • the choice of whether to include an adjuvant (or sub-components thereof) in the stored bulk will depend on factors such as the storage conditions (e.g. if freezing is involved) and the characteristics of the adjuvant (e.g. stability under freezing conditions), etc. Delaying these processing steps until after storage also advantageously allows the decision process to be delayed.
  • Bulk vaccine is stored in frozen form after it has been prepared. Storage of bulk aqueous vaccine will generally be at below 0° C., e.g. below ⁇ 10° C. Preferred freezing is at about ⁇ 20° C. Deep freezing at about ⁇ 80° C. can also be used. Freezing between 0° C. and ⁇ 100° C. will be typical.
  • the bulk vaccine is preferably stored for at least 2 months e.g. ⁇ 3 months, ⁇ 4 months, ⁇ 5 months, ⁇ 6 months, ⁇ 7 months, ⁇ 8 months, ⁇ 9 months, ⁇ 10 months, ⁇ 11 months, or longer.
  • the bulk can be stored for over a year, thus allowing stockpiling well in advance of urgent demand. Storage will typically be for less than 5 years.
  • a stored vaccine can be removed from storage and, after any necessary thawing and/or thermal equilibration, can be used for preparing final vaccines.
  • Typical post-storage procedures will include: addition of any further pharmaceutical components, such as adjuvants, etc.; dilution of the bulk to provide the desired final antigen concentration; mixing of antigens from different strains if a multivalent vaccine is desired; and filling into containers (e.g. vials, syringes, etc.).
  • Containers e.g. vials, syringes, etc.
  • Material will not usually be subjected to any further purification after storage (particularly no further antigen purification).
  • the absence of further purification steps means that all components present in the bulk (e.g. detergents, non-HA antigens, etc.) will also be present in the final vaccines, but at lower concentrations.
  • Final inactivated vaccines may include between 0.1 and 150 ⁇ g of HA per influenza strain, preferably between 0.1 and 50 ⁇ g e.g. 0.1-20 ⁇ g, 0.1-15 ⁇ g, 0.1-10 ⁇ g, 0.1-7.5 ⁇ g, 0.5-5 ⁇ g, etc. Particular doses include e.g. about 15, about 10, about 7.5, about 5, about 3.8, about 1.9, about 1.5, etc. per strain. These lower doses are most useful when an adjuvant is present in the vaccine.
  • Final live vaccines may have a TCID 50 of between 10 6 and 10 8 . The volumes and concentrations of materials used in post-storage steps will be selected to provide these doses in the final vaccines.
  • Containers for final vaccines include vials, syringes (e.g. disposable syringes), nasal sprays, etc. These containers should be sterile.
  • the vial is preferably made of a glass or plastic material.
  • the vial is preferably sterilized before the composition is added to it.
  • vials are preferably sealed with a latex-free stopper, and the absence of latex in all packaging material is preferred.
  • a vial may include a single dose of vaccine, or may include more than one dose (a ‘multidose’ vial) e.g. 10 doses.
  • Preferred vials are made of colorless glass.
  • a vial can have a cap (e.g. a Luer lock) adapted such that a pre-filled syringe can be inserted into the cap, the contents of the syringe can be expelled into the vial (e.g. to reconstitute lyophilised material therein), and the contents of the vial can be removed back into the syringe.
  • a needle can then be attached and the composition can be administered to a patient.
  • the cap is preferably located inside a seal or cover, such that the seal or cover has to be removed before the cap can be accessed.
  • a vial may have a cap that permits aseptic removal of its contents, particularly for multidose vials.
  • the syringe may have a needle attached to it. If a needle is not attached, a separate needle may be supplied with the syringe for assembly and use. Such a needle may be sheathed. Safety needles are preferred. 1-inch 23-gauge, 1-inch 25-gauge and 5 ⁇ 8-inch 25-gauge needles are typical. Syringes may be provided with peel-off labels on which the lot number, influenza season and expiration date of the contents may be printed, to facilitate record keeping.
  • the plunger in the syringe preferably has a stopper to prevent the plunger from being accidentally removed during aspiration.
  • the syringes may have a latex rubber cap and/or plunger.
  • Disposable syringes contain a single dose of vaccine.
  • the syringe will generally have a tip cap to seal the tip prior to attachment of a needle, and the tip cap is preferably made of a butyl rubber. If the syringe and needle are packaged separately then the needle is preferably fitted with a butyl rubber shield.
  • Preferred syringes are those marketed under the trade name “Tip-Lok”TM.
  • Containers may be marked to show a half-dose volume e.g. to facilitate delivery to children.
  • a syringe containing a 0.5 ml dose may have a mark showing a 0.25 ml volume.
  • a glass container e.g. a syringe or a vial
  • a container made from a borosilicate glass rather than from a soda lime glass.
  • a composition may be packaged (e.g. in the same box) with a leaflet including details of the vaccine e.g. instructions for administration, details of the antigens within the vaccine, etc.
  • the instructions may also contain warnings e.g. to keep a solution of adrenaline readily available in case of anaphylactic reaction following vaccination, etc.
  • Typical adjuvants for use with influenza vaccines include, but are not limited to:
  • Compositions may include two or more of said adjuvants.
  • they may advantageously include both an oil-in-water emulsion and a cytokine-inducing agent, as this combination improves the cytokine responses elicited by influenza vaccines, such as the interferon- ⁇ response, with the improvement being much greater than seen when either the emulsion or the agent is used on its own.
  • Antigens and adjuvants in a composition will typically be in admixture.
  • Oil-in-water emulsions have been found to be particularly suitable for use in adjuvanting influenza virus vaccines.
  • Various such emulsions are known, and they typically include at least one oil and at least one surfactant, with the oil(s) and surfactant(s) being biodegradable (metabolisable) and biocompatible.
  • the oil droplets in the emulsion are generally less than 5 ⁇ m in diameter, and may even have a sub-micron diameter, with these small sizes being achieved with a microfluidiser to provide stable emulsions. Droplets with a size less than 220 nm are preferred as they can be subjected to filter sterilization.
  • the invention can be used with oils such as those from an animal (such as fish) or vegetable source.
  • Sources for vegetable oils include nuts, seeds and grains. Peanut oil, soybean oil, coconut oil, and olive oil, the most commonly available, exemplify the nut oils.
  • Jojoba oil can be used e.g. obtained from the jojoba bean. Seed oils include safflower oil, cottonseed oil, sunflower seed oil, sesame seed oil and the like. In the grain group, corn oil is the most readily available, but the oil of other cereal grains such as wheat, oats, rye, rice, teff, triticale and the like may also be used.
  • 6-10 carbon fatty acid esters of glycerol and 1,2-propanediol may be prepared by hydrolysis, separation and esterification of the appropriate materials starting from the nut and seed oils.
  • Fats and oils from mammalian milk are metabolizable and may therefore be used in the practice of this invention.
  • the procedures for separation, purification, saponification and other means necessary for obtaining pure oils from animal sources are well known in the art.
  • Most fish contain metabolizable oils which may be readily recovered. For example, cod liver oil, shark liver oils, and whale oil such as spermaceti exemplify several of the fish oils which may be used herein.
  • a number of branched chain oils are synthesized biochemically in 5-carbon isoprene units and are generally referred to as terpenoids.
  • Shark liver oil contains a branched, unsaturated terpenoids known as squalene, 2,6,10,15,19,23-hexamethyl-2,6,10,14,18,22-tetracosahexaene, which is particularly preferred herein.
  • Squalane the saturated analog to squalene
  • Fish oils, including squalene and squalane are readily available from commercial sources or may be obtained by methods known in the art. Other preferred oils are the tocopherols (see below). Mixtures of oils can be used.
  • Surfactants can be classified by their ‘HLB’ (hydrophile/lipophile balance). Preferred surfactants of the invention have a HLB of at least 10, preferably at least 15, and more preferably at least 16.
  • the invention can be used with surfactants including, but not limited to: the polyoxyethylene sorbitan esters surfactants (commonly referred to as the Tweens), especially polysorbate 20 and polysorbate 80; copolymers of ethylene oxide (EO), propylene oxide (PO), and/or butylene oxide (BO), sold under the DOWFAXTM tradename, such as linear EO/PO block copolymers; octoxynols, which can vary in the number of repeating ethoxy(oxy-1,2-ethanediyl) groups, with octoxynol-9 (Triton X-100, or t-octylphenoxypolyethoxyethanol) being of particular interest; (octylphenoxy)polyethoxyethanol
  • Non-ionic surfactants are preferred.
  • Preferred surfactants for including in the emulsion are Tween 80 (polyoxyethylene sorbitan monooleate), Span 85 (sorbitan trioleate), lecithin and Triton X-100.
  • surfactants can be used e.g. Tween 80/Span 85 mixtures.
  • a combination of a polyoxyethylene sorbitan ester such as polyoxyethylene sorbitan monooleate (Tween 80) and an octoxynol such as t-octylphenoxypolyethoxyethanol (Triton X-100) is also suitable.
  • Another useful combination comprises laureth 9 plus a polyoxyethylene sorbitan ester and/or an octoxynol.
  • Preferred amounts of surfactants are: polyoxyethylene sorbitan esters (such as Tween 80) 0.01 to 1%, in particular about 0.1%; octyl- or nonylphenoxy polyoxyethanols (such as Triton X-100, or other detergents in the Triton series) 0.001 to 0.1%, in particular 0.005 to 0.02%; polyoxyethylene ethers (such as laureth 9) 0.1 to 20%, preferably 0.1 to 10% and in particular 0.1 to 1% or about 0.5%.
  • polyoxyethylene sorbitan esters such as Tween 80
  • octyl- or nonylphenoxy polyoxyethanols such as Triton X-100, or other detergents in the Triton series
  • polyoxyethylene ethers such as laureth 9
  • oil-in-water emulsion adjuvants useful with the invention include, but are not limited to:
  • Emulsions will generally be added to a liquid antigen preparation.
  • the volume ratio of the two liquids for mixing can vary (e.g. between 5:1 and 1:5) but is generally about 1:1.
  • haemagglutininin antigen will generally remain in aqueous solution but may distribute itself around the oil/water interface. In general, little if any haemagglutinin will enter the oil phase of the emulsion.
  • composition includes a tocopherol
  • any of the ⁇ , ⁇ , ⁇ , ⁇ , ⁇ or ⁇ tocopherols can be used, but ⁇ -tocopherols are preferred.
  • the tocopherol can take several forms e.g. different salts and/or isomers. Salts include organic salts, such as succinate, acetate, nicotinate, etc. D- ⁇ -tocopherol and DL- ⁇ -tocopherol can both be used.
  • Tocopherols are advantageously included in vaccines for use in elderly patients (e.g. aged 60 years or older) because vitamin E has been reported to have a positive effect on the immune response in this patient group [112].
  • a preferred ⁇ -tocopherol is DL- ⁇ -tocopherol, and the preferred salt of this tocopherol is the succinate.
  • the succinate salt has been found to cooperate with TNF-related ligands in vivo.
  • ⁇ -tocopherol succinate is known to be compatible with influenza vaccines and to be a useful preservative as an alternative to mercurial compounds [46].
  • Cytokine-inducing agents for inclusion in compositions of the invention are able, when administered to a patient, to elicit the immune system to release cytokines, including interferons and interleukins. Cytokine responses are known to be involved in the early and decisive stages of host defense against influenza infection [114]. Preferred agents can elicit the release of one or more of: interferon- ⁇ ; interleukin-1; interleukin-2; interleukin-12; TNF- ⁇ ; TNF- ⁇ ; and GM-CSF. Preferred agents elicit the release of cytokines associated with a Th1-type immune response e.g. interferon- ⁇ , TNF- ⁇ , interleukin-2. Stimulation of both interferon- ⁇ and interleukin-2 is preferred.
  • a patient will have T cells that, when stimulated with an influenza antigen, will release the desired cytokine(s) in an antigen-specific manner.
  • T cells purified form their blood will release ⁇ -interferon when exposed in vitro to influenza virus haemagglutinin.
  • Methods for measuring such responses in peripheral blood mononuclear cells (PBMC) are known in the art, and include ELISA, ELISPOT, flow-cytometry and real-time PCR.
  • reference 115 reports a study in which antigen-specific T cell-mediated immune responses against tetanus toxoid, specifically ⁇ -interferon responses, were monitored, and found that ELISPOT was the most sensitive method to discriminate antigen-specific TT-induced responses from spontaneous responses, but that intracytoplasmic cytokine detection by flow cytometry was the most efficient method to detect re-stimulating effects.
  • Suitable cytokine-inducing agents include, but are not limited to:
  • the cytokine-inducing agents for use in the present invention may be modulators and/or agonists of Toll-Like Receptors (TLR).
  • TLR Toll-Like Receptors
  • they may be agonists of one or more of the human TLR1, TLR2, TLR3, TLR4, TLR7, TLR8, and/or TLR9 proteins.
  • Preferred agents are agonists of TLR7 (e.g. imidazoquinolines) and/or TLR9 (e.g. CpG oligonucleotides). These agents are useful for activating innate immunity pathways.
  • the cytokine-inducing agent can be added to the composition at various stages during its production. For example, it may be within an antigen composition, and this mixture can then be added to an oil-in-water emulsion. As an alternative, it may be within an oil-in-water emulsion, in which case the agent can either be added to the emulsion components before emulsification, or it can be added to the emulsion after emulsification. Similarly, the agent may be coacervated within the emulsion droplets.
  • the location and distribution of the cytokine-inducing agent within the final composition will depend on its hydrophilic/lipophilic properties e.g. the agent can be located in the aqueous phase, in the oil phase, and/or at the oil-water interface.
  • the cytokine-inducing agent can be conjugated to a separate agent, such as an antigen (e.g. CRM197).
  • a separate agent such as an antigen (e.g. CRM197).
  • an antigen e.g. CRM197
  • the adjuvants may be non-covalently associated with additional agents, such as by way of hydrophobic or ionic interactions.
  • Two preferred cytokine-inducing agents are (a) immunostimulatory oligonucleotides and (b) 3dMPL.
  • Immunostimulatory oligonucleotides can include nucleotide modifications/analogs such as phosphorothioate modifications and can be double-stranded or (except for RNA) single-stranded.
  • References 145, 146 and 147 disclose possible analog substitutions e.g. replacement of guanosine with 2′-deoxy-7-deazaguanosine.
  • the adjuvant effect of CpG oligonucleotides is further discussed in refs. 148-153.
  • a CpG sequence may be directed to TLR9, such as the motif GTCGTT or TTCGTT [154].
  • the CpG sequence may be specific for inducing a Th1 immune response, such as a CpG-A ODN (oligodeoxynucleotide), or it may be more specific for inducing a B cell response, such a CpG-B ODN.
  • CpG-A and CpG-B ODNs are discussed in refs. 155-157.
  • the CpG is a CpG-A ODN.
  • the CpG oligonucleotide is constructed so that the 5′ end is accessible for receptor recognition.
  • two CpG oligonucleotide sequences may be attached at their 3′ ends to form “immunomers”. See, for example, references 154 & 158-160.
  • a useful CpG adjuvant is CpG7909, also known as ProMuneTM (Coley Pharmaceutical Group, Inc.).
  • TpG sequences can be used [161]. These oligonucleotides may be free from unmethylated CpG motifs.
  • the immunostimulatory oligonucleotide may be pyrimidine-rich.
  • it may comprise more than one consecutive thymidine nucleotide (e.g. TTTT, as disclosed in ref. 161), and/or it may have a nucleotide composition with >25% thymidine (e.g. >35%, >40%, >50%, >60%, >80%, etc.).
  • it may comprise more than one consecutive cytosine nucleotide (e.g. CCCC, as disclosed in ref. 161), and/or it may have a nucleotide composition with >25% cytosine (e.g. >35%, >40%, >50%, >60%, >80%, etc.).
  • These oligonucleotides may be free from unmethylated CpG motifs.
  • Immunostimulatory oligonucleotides will typically comprise at least 20 nucleotides. They may comprise fewer than 100 nucleotides.
  • 3dMPL (also known as 3 de-O-acylated monophosphoryl lipid A or 3-O-desacyl-4′-monophosphoryl lipid A) is an adjuvant in which position 3 of the reducing end glucosamine in monophosphoryl lipid A has been de-acylated.
  • 3dMPL has been prepared from a heptoseless mutant of Salmonella minnesota , and is chemically similar to lipid A but lacks an acid-labile phosphoryl group and a base-labile acyl group. It activates cells of the monocyte/macrophage lineage and stimulates release of several cytokines, including IL-1, IL-12, TNF- ⁇ and GM-CSF (see also ref. 162). Preparation of 3dMPL was originally described in reference 163, and the product has been manufactured and sold by Corixa Corporation under the name MPLTM. Further details can be found in refs 116 to 119.
  • 3dMPL can take the form of a mixture of related molecules, varying by their acylation (e.g. having 3, 4, 5 or 6 acyl chains, which may be of different lengths).
  • the two glucosamine (also known as 2-deoxy-2-amino-glucose) monosaccharides are N-acylated at their 2-position carbons (i.e. at positions 2 and 2′), and there is also O-acylation at the 3′ position.
  • the group attached to carbon 2 has formula —NH—CO—CH 2 —CR 1 R 1′ .
  • the group attached to carbon 2′ has formula —NH—CO—CH 2 —CR 2 R 2′ .
  • the group attached to carbon 3′ has formula —O—CO—CH 2 —CR 3 R 3′ .
  • a representative structure is:
  • Groups R 1 , R 2 and R 3 are each independently —(CH 2 ) n —CH 3 .
  • the value of n is preferably between 8 and 16, more preferably between 9 and 12, and is most preferably 10.
  • Groups R 1′ , R 2′ and R 3′ can each independently be: (a)—H; (b)—OH; or (c)—O—CO—R 4 , where R 4 is either —H or —(CH 2 ) m —CH 3 , wherein the value of m is preferably between 8 and 16, and is more preferably 10, 12 or 14. At the 2 position, m is preferably 14. At the 2′ position, m is preferably 10. At the 3′ position, m is preferably 12.
  • Groups R 1′ , R 2′ and R 3′ are thus preferably —O-acyl groups from dodecanoic acid, tetradecanoic acid or hexadecanoic acid.
  • the 3dMPL has only 3 acyl chains (one on each of positions 2, 2′ and 3′).
  • the 3dMPL can have 4 acyl chains.
  • the 3dMPL can have 5 acyl chains.
  • the 3dMPL can have 6 acyl chains.
  • the 3dMPL adjuvant used according to the invention can be a mixture of these forms, with from 3 to 6 acyl chains, but it is preferred to include 3dMPL with 6 acyl chains in the mixture, and in particular to ensure that the hexaacyl chain form makes up at least 10% by weight of the total 3dMPL e.g. ⁇ 20%, ⁇ 30%, ⁇ 40%, ⁇ 50% or more. 3dMPL with 6 acyl chains has been found to be the most adjuvant-active form.
  • 3dMPL for inclusion in compositions of the invention is:
  • references to amounts or concentrations of 3dMPL in compositions of the invention refer to the combined 3dMPL species in the mixture.
  • 3dMPL can form micellar aggregates or particles with different sizes e.g. with a diameter ⁇ 150 nm or >500 nm. Either or both of these can be used with the invention, and the better particles can be selected by routine assay. Smaller particles (e.g. small enough to give a clear aqueous suspension of 3dMPL) are preferred for use according to the invention because of their superior activity [164]. Preferred particles have a mean diameter less than 220 nm, more preferably less than 200 nm or less than 150 nm or less than 120 nm, and can even have a mean diameter less than 100 nm. In most cases, however, the mean diameter will not be lower than 50 nm.
  • Particle diameter can be assessed by the routine technique of dynamic light scattering, which reveals a mean particle diameter. Where a particle is said to have a diameter of x nm, there will generally be a distribution of particles about this mean, but at least 50% by number (e.g. ⁇ 60%, ⁇ 70%, ⁇ 80%, ⁇ 90%, or more) of the particles will have a diameter within the range x ⁇ 25%.
  • 3dMPL can advantageously be used in combination with an oil-in-water emulsion. Substantially all of the 3dMPL may be located in the aqueous phase of the emulsion.
  • the 3dMPL can be used on its own, or in combination with one or more further compounds.
  • 3dMPL in combination with the QS21 saponin [165] (including in an oil-in-water emulsion [166]), with an immunostimulatory oligonucleotide, with both QS21 and an immunostimulatory oligonucleotide, with aluminum phosphate [167], with aluminum hydroxide [168], or with both aluminum phosphate and aluminum hydroxide.
  • the adjuvants known as aluminum hydroxide and aluminum phosphate may be used. These names are conventional, but are used for convenience only, as neither is a precise description of the actual chemical compound which is present (e.g. see chapter 9 of reference 104).
  • the invention can use any of the “hydroxide” or “phosphate” adjuvants that are in general use as adjuvants.
  • aluminium hydroxide typically aluminium oxyhydroxide salts, which are usually at least partially crystalline.
  • Aluminium oxyhydroxide which can be represented by the formula AlO(OH)
  • IR infrared
  • the degree of crystallinity of an aluminium hydroxide adjuvant is reflected by the width of the diffraction band at half height (WHH), with poorly-crystalline particles showing greater line broadening due to smaller crystallite sizes.
  • the surface area increases as WHH increases, and adjuvants with higher WHH values have been seen to have greater capacity for antigen adsorption.
  • a fibrous morphology e.g. as seen in transmission electron micrographs
  • the pl of aluminium hydroxide adjuvants is typically about 11 i.e. the adjuvant itself has a positive surface charge at physiological pH.
  • Adsorptive capacities of between 1.8-2.6 mg protein per mg Al +++ at pH 7.4 have been reported for aluminium hydroxide adjuvants.
  • the adjuvants known as “aluminium phosphate” are typically aluminium hydroxyphosphates, often also containing a small amount of sulfate (i.e. aluminium hydroxyphosphate sulfate). They may be obtained by precipitation, and the reaction conditions and concentrations during precipitation influence the degree of substitution of phosphate for hydroxyl in the salt. Hydroxyphosphates generally have a PO 4 /Al molar ratio between 0.3 and 1.2. Hydroxyphosphates can be distinguished from strict AlPO 4 by the presence of hydroxyl groups. For example, an IR spectrum band at 3164 cm ⁇ 1 (e.g. when heated to 200° C.) indicates the presence of structural hydroxyls [ch. 9 of ref. 104].
  • the PO 4 /Al 3+ molar ratio of an aluminium phosphate adjuvant will generally be between 0.3 and 1.2, preferably between 0.8 and 1.2, and more preferably 0.95 ⁇ 0.1.
  • the aluminium phosphate will generally be amorphous, particularly for hydroxyphosphate salts.
  • a typical adjuvant is amorphous aluminium hydroxyphosphate with PO 4 /Al molar ratio between 0.84 and 0.92, included at 0.6 mg Al 3+ /ml.
  • the aluminium phosphate will generally be particulate (e.g. plate-like morphology as seen in transmission electron micrographs). Typical diameters of the particles are in the range 0.5-20 ⁇ m (e.g. about 5-10 ⁇ m) after any antigen adsorption.
  • Adsorptive capacities of between 0.7-1.5 mg protein per mg Al +++ at pII 7.4 have been reported for aluminium phosphate adjuvants.
  • Suspensions of aluminium salts used to prepare compositions of the invention may contain a buffer (e.g. a phosphate or a histidine or a Tris buffer), but this is not always necessary.
  • the suspensions are preferably sterile and pyrogen-free.
  • a suspension may include free aqueous phosphate ions e.g. present at a concentration between 1.0 and 20 mM, preferably between 5 and 15 mM, and more preferably about 10 mM.
  • the suspensions may also comprise sodium chloride.
  • the invention can use a mixture of both an aluminium hydroxide and an aluminium phosphate [49].
  • there may be more aluminium phosphate than hydroxide e.g. a weight ratio of at least 2:1 e.g. ⁇ 5:1, ⁇ 6:1, ⁇ 7:1, ⁇ 8:1, ⁇ 9:1, etc.
  • the concentration of Al +++ in a composition for administration to a patient is preferably less than 10 mg/ml e.g. ⁇ 5 mg/ml, ⁇ 4 mg/ml, ⁇ 3 mg/ml, ⁇ 2 mg/ml, ⁇ 1 mg/ml, etc.
  • a preferred range is between 0.3 and 1 mg/ml.
  • a maximum of ⁇ 0.85 mg/dose is preferred.
  • the adjuvant component may include one or more further adjuvant or immunostimulating agents.
  • additional components include, but are not limited to: a 3-O-deacylated monophosphoryl lipid A adjuvant (‘3d-MPL’); and/or an oil-in-water emulsion.
  • Final vaccines of the invention are pharmaceutically acceptable. They may include components in addition to the influenza antigen e.g. they will typically include one or more pharmaceutical carrier(s) and/or excipient(s). A thorough discussion of such components is available in ref. 169.
  • the composition may include preservatives such as thiomersal or 2-phenoxyethanol. It is preferred, however, that the vaccine should be substantially free from (i.e. less than 5 ⁇ g/ml) mercurial material e.g. thiomersal-free [46,170]. Vaccines containing no mercury are more preferred. Preservatives may be added to a bulk vaccine before freezing and/or after thawing. Preservative-free vaccines are particularly preferred.
  • a physiological salt such as a sodium salt.
  • Sodium chloride (NaCl) is preferred, which may be present at between 1 and 20 mg/ml.
  • Other salts that may be present include potassium chloride, potassium dihydrogen phosphate, disodium phosphate dehydrate, magnesium chloride, calcium chloride, etc. These salts may be added to a bulk vaccine before freezing and/or after thawing. Adding before freezing is preferred, and potassium dihydrogen phosphate is particularly useful for material which will be frozen.
  • Final vaccines may include one or more buffers.
  • Typical buffers include: a phosphate buffer; a Tris buffer; a borate buffer; a succinate buffer; a histidine buffer (particularly with an aluminum hydroxide adjuvant); or a citrate buffer.
  • Buffers will typically be included in the 5-20 mM range. Buffering substances may be added to a bulk vaccine before freezing and/or after thawing. Adding before freezing is preferred, and a phosphate buffer is particularly useful for material which will be frozen.
  • Final vaccines will generally have an osmolality of between 200 mOsm/kg and 400 mOsm/kg, preferably between 240-360 mOsm/kg, and will more preferably fall within the range of 290-310 mOsm/kg. Osmolality has previously been reported not to have an impact on pain caused by vaccination [171], but keeping osmolality in this range is nevertheless preferred.
  • the pH of a final vaccine will generally be between 5.0 and 8.1, and more typically between 6.0 and 8.0 e.g. between 6.5 and 7.5, or between 7.0 and 7.8. pH may be adjusted in a bulk vaccine before freezing and/or after thawing. Adjustment before freezing is preferred.
  • Final vaccines are preferably sterile. They are preferably non-pyrogenic e.g. containing ⁇ 1 EU (endotoxin unit, a standard measure) per dose, and preferably ⁇ 0.1 EU per dose. They are preferably gluten free.
  • Final vaccines may include material for a single immunisation, or may include material for multiple immunisations (i.e. a ‘multidose’ kit).
  • a preservative is preferred in multidose arrangements and/or, as mentioned above, an aseptic cap can be used.
  • Influenza vaccines are typically administered in a dosage volume of about 0.5 ml, although a half dose (i.e. about 0.25 ml) may be administered to children.
  • Final vaccine compositions are preferably stored at between 2° C. and 8° C. Unlike the stored bulk, they should not be frozen. They should ideally be kept out of direct light.
  • compositions of the invention are suitable for administration to human patients, and the invention provides a method of raising an immune response in a patient, comprising the step of administering a vaccine to the patient, where the vaccine was prepared using a method of the invention.
  • the invention also provides a vaccine prepared according to the invention, for use as a medicament.
  • the invention also provides the use of a frozen bulk influenza antigen preparation in the manufacture of a medicament for raising an immune response in a patient.
  • the immune response raised by these methods and uses will generally include an antibody response, preferably a protective antibody response.
  • Methods for assessing antibody responses, neutralising capability and protection after influenza virus vaccination are well known in the art. Human studies have shown that antibody titers against hemagglutinin of human influenza virus are correlated with protection (a serum sample hemagglutination-inhibition titer of about 30-40 gives around 50% protection from infection by a homologous virus) [172].
  • Antibody responses are typically measured by hemagglutination inhibition, by microneutralisation, by single radial immunodiffusion (SRID), and/or by single radial hemolysis (SRH). These assay techniques are well known in the art.
  • compositions of the invention can be administered in various ways.
  • the most preferred immunisation route is by intramuscular injection (e.g. into the arm or leg), but other available routes include subcutaneous injection, intranasal [173-175], oral [176], intradermal [177,178], transcutaneous, transdermal [179], etc.
  • Vaccines prepared according to the invention may be used to treat both children and adults. Influenza vaccines are currently recommended for use in pediatric and adult immunisation, from the age of 6 months. Thus the patient may be less than 1 year old, 1-5 years old, 5-15 years old, 15-55 years old, or at least 55 years old.
  • Preferred patients for receiving the vaccines are the elderly (e.g. ⁇ 50 years old, ⁇ 60 years old, preferably ⁇ 65 years), the young (e.g. ⁇ 5 years old), hospitalised patients, healthcare workers, armed service and military personnel, pregnant women, the chronically ill, immunodeficient patients, patients who have taken an antiviral compound (e.g.
  • an oseltamivir or zanamivir compound in the 7 days prior to receiving the vaccine, people with egg allergies and people travelling abroad.
  • the vaccines are not suitable solely for these groups, however, and may be used more generally in a population. For pandemic strains, administration to all age groups is preferred.
  • compositions satisfy 1, 2 or 3 of the CPMP criteria for efficacy.
  • these criteria are: (1) ⁇ 70% seroprotection; (2) ⁇ 40% seroconversion; and/or (3) a GMT increase of ⁇ 2.5-fold.
  • these criteria are: (1) ⁇ 60% seroprotection; (2) ⁇ 30% seroconversion; and/or (3) a GMT increase of ⁇ 2-fold.
  • Treatment can be by a single dose schedule or a multiple dose schedule. Multiple doses may be used in a primary immunisation schedule and/or in a booster immunisation schedule. In a multiple dose schedule the various doses may be given by the same or different routes e.g. a parenteral prime and mucosal boost, a mucosal prime and parenteral boost, etc. Administration of more than one dose (typically two doses) is particularly useful in immunologically na ⁇ ve patients e.g. for people who have never received an influenza vaccine before, or for vaccinating against a new HA subtype (as in a pandemic outbreak). Multiple doses will typically be administered at least 1 week apart (e.g. about 2 weeks, about 3 weeks, about 4 weeks, about 6 weeks, about 8 weeks, about 12 weeks, about 16 weeks, etc.).
  • Vaccines of the invention may be administered to patients at substantially the same time as (e.g. during the same medical consultation or visit to a healthcare professional or vaccination centre) other vaccines e.g. at substantially the same time as a measles vaccine, a mumps vaccine, a rubella vaccine, a MMR vaccine, a varicella vaccine, a MMRV vaccine, a diphtheria vaccine, a tetanus vaccine, a pertussis vaccine, a DTP vaccine, a conjugated H.
  • other vaccines e.g. at substantially the same time as a measles vaccine, a mumps vaccine, a rubella vaccine, a MMR vaccine, a varicella vaccine, a MMRV vaccine, a diphtheria vaccine, a tetanus vaccine, a pertussis vaccine, a DTP vaccine, a conjugated H.
  • influenzae type b vaccine an inactivated poliovirus vaccine, a hepatitis B virus vaccine, a meningococcal conjugate vaccine (such as a tetravalent A-C-W135-Y vaccine), a respiratory syncytial virus vaccine, a pneumococcal conjugate vaccine, etc.
  • Administration at substantially the same time as a pneumococcal vaccine and/or a meningococcal vaccine is particularly useful in elderly patients.
  • vaccines of the invention may be administered to patients at substantially the same time as (e.g. during the same medical consultation or visit to a healthcare professional) an antiviral compound, and in particular an antiviral compound active against influenza virus (e.g. oseltamivir and/or zanamivir).
  • an antiviral compound active against influenza virus e.g. oseltamivir and/or zanamivir.
  • neuraminidase inhibitors such as a (3R,4R,5S)-4-acetylamino-5-amino-3(1-ethylpropoxy)-1-cyclohexene-1-carboxylic acid or 5-(acetylamino)-4-[(aminoiminomethyl)-amino]-2,6-anhydro-3,4,5-trideoxy-D-glycero-D-galactonon-2-enonic acid, including esters thereof (e.g. the ethyl esters) and salts thereof (e.g. the phosphate salts).
  • esters thereof e.g. the ethyl esters
  • salts thereof e.g. the phosphate salts
  • a preferred antiviral is (3R,4R,5S)-4-acetylamino-5-amino-3(1-ethylpropoxy)-1-cyclohexene-1-carboxylic acid, ethyl ester, phosphate (1:1), also known as oseltamivir phosphate (TAMIFLUTM).
  • composition “comprising” encompasses “including” as well as “consisting” e.g. a composition “comprising” X may consist exclusively of X or may include something additional e.g. X+Y.
  • a process comprising a step of mixing two or more components does not require any specific order of mixing.
  • components can be mixed in any order. Where there are three components then two components can be combined with each other, and then the combination may be combined with the third component, etc.
  • animal (and particularly bovine) materials are used in the culture of cells, they should be obtained from sources that are free from transmissible spongiform encaphalopathies (TSEs), and in particular free from bovine spongiform encephalopathy (BSE). Overall, it is preferred to culture cells in the total absence of animal-derived materials.
  • TSEs transmissible spongiform encaphalopathies
  • BSE bovine spongiform encephalopathy
  • a compound is administered to the body as part of a composition then that compound may alternatively be replaced by a suitable prodrug.
  • a cell substrate is used for reassortment or reverse genetics procedures, it is preferably one that has been approved for use in human vaccine production e.g. as in Ph Eur general chapter 5.2.3.
  • Bulk preparation and/or storage and/or downstream processing steps may take place within the same country or within different countries. For instance, bulk could be prepared in Europe and exported to the USA, with frozen storage taking place in the USA.
  • Influenza virus A/Wyoming H3N2 is grown in MDCK cell culture in a fermenter by incubating the seed virus with the cells for two days at 35° C. After viral growth, the pH of the fermenter fluid is raised to about 8 by adding of dilute sodium hydroxide, and DNase is added. The culture is maintained at 35° C. for four more hours. The culture fluid is then filtered through a depth filter with a nominal pore size of 0.5 ⁇ m to remove cellular debris.
  • the resulting suspension of virions is concentrated and purified by ultrafiltration using a membrane with a 300 kDa cut-off.
  • Sucrose is added to the concentrate to a final concentration of 30% (w/v) after which formaldehyde is added to a final concentration of 0.015% (w/v). This mixture is stirred at 2-8° C. for 72 hours.
  • the virion concentrate is then further purified. Tween 80TM is added to a final concentration of 300 ⁇ g/ml and cetyltrimethylammonium bromide (CTAB) is added to a final concentration of 750 pg/ml. This mixture is stirred at 4° C. for three hours, and centrifuged. Collected antigen is incubated overnight at 2-8° C.
  • CTAB cetyltrimethylammonium bromide
  • the HA concentration in the final purified antigen suspension is 400 ⁇ g/ml. Half of this suspension is frozen at ⁇ 20° C. for future use as a bulk vaccine, and the other half is diluted and formulated as a monovalent vaccine for patient administration.
  • the frozen bulk vaccine can be thawed and then continue to be used in the same way as the unfrozen bulk vaccine.

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WO2008017956A3 (fr) 2008-07-24
GB0614460D0 (en) 2006-08-30

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